CN112739298B - 用于吸收剂制品的流体分布材料 - Google Patents

用于吸收剂制品的流体分布材料 Download PDF

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Publication number
CN112739298B
CN112739298B CN201980042129.XA CN201980042129A CN112739298B CN 112739298 B CN112739298 B CN 112739298B CN 201980042129 A CN201980042129 A CN 201980042129A CN 112739298 B CN112739298 B CN 112739298B
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Prior art keywords
fluid distribution
film layer
distribution material
projections
facing side
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Expired - Fee Related
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CN201980042129.XA
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CN112739298A (zh
Inventor
A·D·马奇诺
M·E·费舍尔
B·C·卢米思
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Feiteshi Film Products Co ltd
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Feiteshi Film Products Co ltd
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    • Y10T428/24331—Composite web or sheet including nonapertured component
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract

一种用于吸收剂制品的流体分布材料，其包含具有第一和第二侧，并且基重是约10gsm至约25gsm的成形膜层，和基重是约10gsm至约15gsm，并且层合到该成形膜层的非织物层。该成形膜层包含以具有10至40个凸起/线性英寸的图案排列的多个有孔凸起。该凸起每个包含从第一侧延伸的连续侧壁，并且第二侧具有与该多个凸起对齐的多个孔和位于该孔之间的槽脊区域。该非织物层包含在该槽脊区域连接到该成形膜层的多个纤维。该材料根据再润湿测试方法的再润湿值小于0.075g。该流体分布材料在0.21psi至0.60psi的压力的压缩率小于10％。

Description

用于吸收剂制品的流体分布材料
交叉参考的相关申请
本国际PCT专利申请依赖于2018年5月25日提交的美国专利申请序列号15/989,852，其于2019年4月16日作为美国专利10,258,517公布，和2019年2月26日提交的美国专利申请序列号16/285,611的优先权，这二者的内容通过参考引入本文。
技术领域
本发明涉及一种流体分布材料，其可以用于吸收剂制品，以及包括该流体分布材料的吸收剂制品。
背景技术
多种公知的吸收剂制品经配置来吸收体液。这种吸收剂制品的例子包括但不限于女性卫生用品例如卫生棉，婴儿尿布，成人失禁产品，和绷带。一种典型的吸收剂制品通常用流体可透过的朝向使用者的顶片(其可以是三维有孔聚合物膜或非织物幅材(web)或膜/非织物层合体)，吸收剂芯和流体不可透过的服装或面朝外的背片(其可以例如是固体聚合物膜)构成。
与吸收剂制品相关的一个潜在问题可能是在吸收剂制品的朝向使用者的顶片被感觉到不够干燥。通常，接触顶片的皮肤感觉越干燥，吸收剂制品就越舒适。在许多情况中，顶片的表面干燥会关系到流体吸渗(strikethrough)效率。如果顶片下面的层在将流体完全排出顶片方面效率低下，则残留湿气可能留下。此外，如果当吸收剂制品经受压力(其是使用者在穿戴该制品时的典型条件)时允许流体从顶片下面的层移动和返回穿过该顶片，则湿气会重新发生和导致残留湿气。
可以将一个或多个另外的层添加到吸收剂制品的顶片与吸收剂芯之间，来改进从顶片出来的流体采集和/或跨过吸收剂芯的流体分布，从而可以将流体更迅速和/或更完全地牵引穿过和离开顶片并且进入吸收剂芯。另外的层可以为非织物材料的形式，例如美国专利8,426,671(通过参考引入本文)所述的液体管理层，或者可以为三维有孔膜的形式，例如美国专利7,378,568(通过参考引入本文)所述的采集分布层，或者例如美国专利申请公布2005/0267429(通过参考引入本文)所述的采集/分布层。但是，这种另外的层增加了最终制品的成本，还会增加制品的厚度或蓬松度和/或刚性。通过例如减量(downgauging)来使另外的层中所用材料的量最小化的努力(特别是对于膜来说)会是挑战性的，因为减量会降低材料的模量和不利地影响在转化过程中将该层引入最终吸收剂制品中的能力。
令人期望的是提供一种流体分布材料，其减少残留的湿气，甚至在吸收剂制品经受压力之后也是如此，并且具有足够的模量来允许该流体分布材料转化成吸收剂制品。
发明内容
根据本发明的一个方面，提供一种用于吸收剂制品的流体分布材料。该流体分布材料包含具有面朝使用者侧和与该面朝使用者侧相对的面朝服装侧的成形膜层。成形膜层包含以具有10至40个凸起/线性英寸的图案排列的多个有孔凸起。每个凸起包含从面朝使用者侧延伸的连续侧壁，和该面朝服装侧具有与该多个有孔凸起对齐的多个孔和位于该孔之间的槽脊区域(land area)。成形膜层的基重是约10gsm至约25gsm。将非织物层层合到成形膜层的面朝服装侧。非织物层包括在槽脊区域处连接到成形膜层的多个纤维，并且基重是约10gsm至约15gsm。流体分布材料根据本文所述的再润湿测试方法的再润湿值小于0.075g。流体分布材料在0.21psi至0.60psi的压力的压缩率小于10％。
在一个实施方案中，多个有孔凸起以具有10至25个凸起/英寸的图案排列。
在一个实施方案中，成形膜层包含表面活性剂。
在一个实施方案中，非织物层包括纺粘非织物。在一个实施方案中，纺粘非织物是亲水的。
在一个实施方案中，成形膜层是高密度聚乙烯(HDPE)。
根据本发明的一个方面，提供一种用于吸收剂制品的流体管理体系。该流体管理体系包括流体分布材料，其包含具有面朝使用者侧和与该面朝使用者侧相对的面朝服装侧的成形膜层。成形膜层包含以具有10至40个凸起/线性英寸的图案排列的多个有孔凸起。每个凸起包含从面朝使用者侧延伸的连续侧壁，和该面朝服装侧具有与该多个有孔凸起对齐的多个孔和位于该孔之间的槽脊区域。成形膜层的基重是约10gsm至约25gsm。流体分布材料还包含层合到成形膜层的面朝服装侧的非织物层。非织物层包括在槽脊区域处连接到成形膜层的多个纤维，并且基重是约10gsm至约15gsm。流体管理体系还包括连接到流体分布材料的顶片。成形膜层的面朝使用者侧面对顶片。流体分布材料根据本文所述的再润湿测试方法的再润湿值小于0.075g。流体分布材料在0.21psi至0.60psi的压力的压缩率小于10％。
在一个实施方案中，多个有孔凸起以具有10至25个凸起/英寸的图案排列。
在一个实施方案中，顶片包括有孔成形膜。
在一个实施方案中，顶片包括非织物幅材。
在一个实施方案中，顶片包括层合体。
在一个实施方案中，成形膜层是高密度聚乙烯(HDPE)。
根据本发明的一个方面，提供一种吸收剂制品，其包含顶片，背片，位于该顶片与该背片之间的吸收剂材料，和位于该顶片与吸收剂芯之间的流体分布材料。流体分布材料包括具有面朝使用者侧和与该面朝使用者侧相对的面朝服装侧的成形膜层。成形膜层包含以具有10至40个凸起/线性英寸的图案排列的多个有孔凸起。每个所述凸起包含从面朝使用者侧延伸并且与顶片接触的连续侧壁，和该面朝服装侧具有与该多个有孔凸起对齐的多个孔和位于该孔之间的槽脊区域。成形膜层的基重是约10gsm至约25gsm。流体分布材料还包括层合到成形膜层的面朝服装侧的非织物层。非织物层包括在槽脊区域处连接到成形膜层的多个纤维，并且基重是约10gsm至约15gsm。流体分布材料根据再润湿测试方法的再润湿值小于0.075g。流体分布材料在0.21psi至0.60psi的压力的压缩率小于10％。
在一个实施方案中，顶片包括有孔成形膜。
在一个实施方案中，顶片包括非织物幅材。
在一个实施方案中，顶片包括层合体。
在一个实施方案中，多个有孔凸起以具有10至25个凸起/英寸的图案排列。
在一个实施方案中，成形膜层是高密度聚乙烯(HDPE)。
本发明的这些和其他方面、特征和特性，以及结构的相关元件和部分的组合的操作方法和功能，和制造经济性，将通过考虑下面的说明和所附权利要求书以及参考附图而变得更清楚可见，其全部形成本说明书的一部分。但是，要明确理解的是，附图仅是用于例示和说明目的，并非打算作为本发明限度的定义。如说明书和权利要求书中所使用，单数形式“一个”、“一种”和“该”包括复数指代物，除非上下文另有明确指示。
附图说明
例示下面附图的部件来强调本发明的总体原理，不必按照尺寸绘制。出于一致和清楚的目的，表示相应部件的附图标记根据需要在整个附图中重复。
图1是根据本发明实施方案的吸收剂制品的示意图；
图2是根据本发明实施方案的图1的吸收剂制品的一部分流体分布材料的示意性放大的横截面侧视图；
图3是图2的流体分布材料的一个实施方案的一侧视图的放大照片；
图4是图3的一部分流体分布材料的放大照片；
图5是图3和4的流体分布材料的部分横截面侧视图的放大照片；
图6是图2的流体分布材料的一个实施方案的一侧视图的放大照片；
图7是图6的一部分流体分布材料的放大照片；
图8是图6和7的流体分布材料的部分横截面侧视图的放大照片；
图9是用于制造根据本发明实施方案的流体分布材料的设备的示意图；
图10是图2的部分流体分布材料的示意性放大横截面侧视图，其中侵入(insult)从上面施加到该流体分布材料；
图11是图10的部分流体分布材料和侵入的示意性放大横截面侧视图，其中该侵入由该流体分布材料处理；
图12是图10和11的部分流体分布材料和侵入的示意性放大横截面侧视图，其中该侵入由该流体分布材料进一步处理；
图13是在侵入已经穿过流体分布材料和进入下面材料之后，图10、11和12的部分流体分布材料和该侵入的示意性放大横截面侧视图；
图14是本发明实施方案和对比样品的吸渗测试结果的图表；
图15是本发明实施方案和对比样品的再润湿测试结果的图表；
图16是流体分布材料的一个实施方案和对比样品的压缩率作为施加压力的函数的图表；
图17是流体分布材料的一个实施方案和对比样品的压缩率作为施加压力的函数的图表；
图18是流体分布材料的一个实施方案和对比样品的压缩率作为施加压力的函数的图表；和
图19是流体分布材料的一个实施方案和对比样品的压缩率作为施加压力的函数的图表。
具体实施方式
现在将细述本发明不同的实施方案。任何一个实施方案的讨论并非打算限制本发明的范围。相反，这些实施方案的方面意在强调本发明的外延，无论是否囊括在权利要求书中。此外，这些实施方案的任何和全部的变化，现在已知的或将来研发的，也意在落入本发明的范围内。
术语表
如本发明所使用，表述“吸收剂制品”和“吸收性器具”表示吸收和容纳体液和其他身体渗出物的制品。更具体地，吸收剂制品/吸收性器具包括靠着和邻近穿戴者的身体布置的服装，来吸收和容纳人体排出的不同渗出物。吸收剂制品的非限定性例子包括但不限于女性卫生用品，婴儿尿布，成人失禁产品，和绷带。
在整个说明书中，术语“幅材”指的是能够卷绕成筒的材料。幅材可以是膜幅材，非织物幅材，层合幅材，有孔层合幅材等。幅材的面指的是它的二维表面之一，与它的边缘之一相对。
术语“复合幅材”或“复合材料”指的是包含以面对面关系彼此连接的两个或更多个单独幅材的幅材。连接可以通过元件幅材的边缘，不过该元件幅材彼此为面对面关系，或者连接可以处于跨过元件幅材的特定点位置，或者连接可以是连续的。
在本说明书中，术语“膜”或“聚合物膜”指的是如下制造的幅材：将熔融的热塑性聚合物材料的帘或片通过流延或吹塑挤出方法进行挤出，然后冷却该片来形成固体聚合物幅材。膜可以是单层膜，共挤出膜，涂覆膜和复合膜。
“涂覆膜”是包含单层膜或共挤出膜的膜，该单层膜或共挤出膜随后用结合到的相同或不同材料的薄层来涂覆(例如挤出涂覆，印模涂覆，印刷等)。
“复合膜”是包含多于一个膜的膜，其中至少两个膜在结合加工中相组合。结合加工可以在膜层之间引入粘结剂层。
在整个说明书中，表述“有孔膜”表示具有多个孔洞的膜，该孔洞从该膜的第一表面延伸到该膜的第二表面。
“二维有孔膜”是孔洞中不存在三维结构的膜，该孔洞然后将平坦膜的第二表面连接到该膜的第一表面。
“成形膜”或“三维膜”是具有从其至少一侧延伸的凸起、突出部或延伸的腔室的膜，和“有孔成形膜”或“三维有孔膜”是孔中存在三维结构(例如孔的深度超过膜的厚度)，或者凸起或突出部或延伸的腔室具有透孔的膜。
如本发明所使用，术语“凸起”指的是包含位于膜的第一表面的平面内的有孔基材部分和大致在膜的第二表面方向上延伸的侧壁部分的三维构件。每个基材部分具有相连的侧壁部分。侧壁部分终止于位于膜的第二表面的平面内的“端部”。凸起的端部可以是有孔的或无孔的。
如本发明所使用，“有孔凸起”指的是在其基材部分或在第二表面的平面内的近端，以及其远端或凸起端具有孔的凸起。在凸起的基材部分中的孔(也称作“初级孔”)可以为多边形的形状，例如正方形、六边形、五边形、椭圆形、圆形、卵形或狭缝，处于规则的或无规的图案。在一个实施方案中，孔可以为船形，如美国专利7,198,836所述，其通过参考引入本文。
有孔的远端或凸起端被称作“次级孔”，并且可以为多边形的形状，例如正方形、六边形、五边形、椭圆形、圆形、卵形、狭缝或船形。有孔凸起的侧壁部分从初级孔延伸到次级孔。
术语“非织物”表示包含多个纤维的幅材。纤维可以彼此结合或者可以是未结合的。纤维可以是短纤维或连续纤维或长丝。纤维可以包含单一材料或者可以包含多种材料，作为不同纤维的组合，或者作为类似纤维的组合，并且每个包含不同材料。
如本发明所使用，“非织物幅材”以它的通常含义来使用，用以定义大致平面的结构，其是相对平坦的、挠性的和多孔的，并且包括短纤维或连续纤维或长丝。非织物幅材可以是用于形成它的任何方法的产物，例如非织物纺粘和熔喷非织物幅材。非织物幅材可以包括幅材的复合物或组合。非织物幅材可以包含任何聚合物材料，由该材料可以生产纤维和/或可以包含棉或其他天然纤维。在一个实施方案中，非织物幅材可以是纺粘材料，由聚丙烯纤维制成。包含不同聚合物的纤维也可以是共混的。在一个实施方案中，纤维可以是所谓的双组分(“bi-co”)纤维，其包含一种材料的芯和另一材料的套。
如本发明所使用，术语“成形结构”或“筛”指的是三维模制设备，其包含用于形成膜中的凸起、延伸的腔室或孔，或者非织物幅材中的凸起的凹陷。在一个实施方案中，成形结构包含具有宽度和直径的管状元件在可选的实施方案中，成形结构可以包含具有宽度和长度的带。横向是与成形结构的宽度平行的方向。纵向是与成形结构的旋转方向平行的方向，并且与横向垂直。
如本发明所使用，术语“使活化”或“活化”指的是将材料拉伸超过其物理性能发生变化的点的过程。在非织物幅材的情况中，对幅材进行足够的活化将使非织物幅材更可拉伸和/或改进它的触觉性质。在一种活化方法中，向材料施加力，使该材料拉伸。聚合物膜和非织物幅材可以例如经机械活化。机械活化过程包括使用机器或设备来向幅材施加力，以引起该幅材拉伸到足以引起该幅材永久变形的程度。用于活化材料的幅材的方法和设备包括但不限于通过互相啮合的齿轮或板来使该幅材活化，通过增量拉伸来使该幅材活化，通过环轧来使该幅材活化，通过拉幅机拉伸、倾斜轮拉伸机或弯曲辊来使该幅材活化，和在夹具或辊堆栈之间在纵向上以不同速度操作来机械拉伸元件以使该幅材活化，及其组合。
本发明的实施方案
图1示意性显示了根据本发明实施方案的吸收剂制品100。如所示的，吸收剂制品100包含顶片110，背片120，和位于顶片110与背片120之间的吸收剂芯130。吸收剂制品100还包含位于顶片110与吸收剂芯130之间的流体分布材料140。
顶片110，其可以为二维或三维有孔膜、非织物幅材、或有孔膜和非织物幅材的层合体的形式，是流体可透过的，并且经配置来面对穿戴吸收剂制品100的使用者和接触该使用者的皮肤。顶片110接收来自于使用者的流体的侵入，并且该流体穿过顶片110到流体分布材料140。流体分布材料140，其实施方案在下面进一步详述，也是可透过的，并且经配置来接收来自于顶片110的流体和将该流体分布到吸收剂芯130。吸收剂芯130，其包含吸收剂材料，接收来自于流体分布材料140的流体和存储该流体，直到吸收剂制品100被废弃。背片120，其是液体不透过的并且可以为聚合物膜或聚合物膜和非织物幅材的层合体的形式，防止液体和其他人体渗出物从吸收剂芯130的底侧泄漏出来。背片120可以是透气的，由此空气而非液体可以穿过。
在一个实施方案中，顶片110和流体分布材料140可以整合形成为流体管理体系150。例如，顶片110和流体分布材料140可以为面对面关系，并且在它们的外周彼此连接，或者可以在多个位置彼此连接，或者跨过幅材连续地形成复合幅材。这种连接可以用一种或多种粘结剂，或通过热结合，或通过超声结合，或通过本领域已知的任何其他连接手段来实现。在一个实施方案中，吸收剂制品100可以不包含顶片110。如果这样，则流体分布材料140可以本身充当流体管理体系，并且经配置与穿戴着吸收剂制品100的使用者接触。
图2示意性显示了根据本发明实施方案的流体分布材料200(其可以用作图1的流体分布材料140)的横截面。如所示的，流体分布材料200包含成形膜层210和非织物层230。成形膜层210具有第一侧212和与第一侧212相对的第二侧214。成形膜层210包含多个有孔凸起216。每个有孔凸起216包含从成形膜层210的第一侧212延伸到远端220(其包含次级孔222)的连续侧壁218，如所示的。成形膜层210的第一侧212还包含位于有孔凸起216之间的槽脊区域224。
成形膜层210的第二侧214具有与多个凸起216对齐的多个初级孔226。同样，成形膜层210的第二侧214中的初级孔226也被认为是有孔凸起216的邻近孔226，而位于有孔凸起216的远端220处的次级孔222也可以被认为是有孔凸起216的远端孔222。成形膜层210的第二侧214还包含位于邻近孔226之间的槽脊区域228。
在一个实施方案中，有孔凸起216可以以具有约10至约40个凸起/线性英寸或“目”，即约10目到约40目的图案来排列。图案可以是六边形图案，正方形图案，交错图案或任何其他类型的图案或设计。在一个实施方案中，有孔凸起216可以以10至25目图案排列。在一个实施方案中，有孔凸起216可以以约11目图案排列。在一个实施方案中，有孔凸起216可以以约22目图案排列。在一个实施方案中，有孔凸起216可以以40目图案排列。在一个实施方案中，邻近孔226可以是六边形形状，并且具有约相同的尺寸。在一个实施方案中，邻近孔226可以具有不同的尺寸和/或形状，如下面进一步详细描述的。
成形膜层210的聚合物可以包括一种或多种聚烯烃，包括但不限于聚乙烯、超低密度聚乙烯、低密度聚乙烯、线性低密度聚乙烯、线性中密度聚乙烯、高密度聚乙烯、聚丙烯、乙烯-乙酸乙烯酯、茂金属，以及其他聚合物。其他聚合物包括但不限于弹性体聚合物，包括但不限于聚丙烯基弹性体、乙烯基弹性体、共聚酯基弹性体、烯烃嵌段共聚物、苯乙烯嵌段共聚物等，或其组合。添加剂例如表面活性剂、填料、着色剂、遮光剂和/或本领域已知的其他添加剂也可以用于成形膜层210中。
再参见图2，非织物层230具有第一侧232和与第一侧232相对的第二侧234。在所示的实施方案中，非织物层230的第一侧232与成形膜层210的第二侧214接触。非织物层230包含多个纤维236。
可以用于非织物层230的非织物幅材可以由许多方法形成，包括但不限于纺粘方法，熔喷方法，水力缠结方法，水刺方法，空气敷设，和结合的梳理辅材方法，或其组合，如非织物领域已知的。在一个实施方案中，非织物层230可以是纺粘的非织物幅材。在一个实施方案中，非织物层230中的纤维236可以是聚丙烯纤维。在一个实施方案中，非织物层230可以包括天然纤维例如棉纤维。
在一个实施方案中，成形膜层210是在结合位置240连接到非织物层230，在这里非织物层230的第一侧232与成形膜层210的第二表面214的槽脊区域228接触。在一个实施方案中，将位于结合位置240的纤维236嵌入成形膜层210的槽脊区域228中，其可以通过真空成形层合方法来完成，如下面进一步详述的。结合位置240预期按图案分布，与槽脊区域228的一些或全部相匹配。
图3是根据本发明的一个实施方案的流体分布材料300的一侧的放大照片，流体分布材料300可以用作图1的流体分布材料140。如所示的，流体分布材料300包含成形膜层310和位于成形膜层310的上面的非织物层330。成形膜层310包含孔326和在孔326之间延伸的槽脊区域328。非织物层330包含多个连续纤维336，其跨过成形膜层310的槽脊区域328和孔326延伸。连续纤维336在结合位置340处连接到槽脊区域328。
图4显示了孔326、槽脊区域328和结合位置340的更近的视图。
图5是图3的流体分布材料300的部分横截面视图的放大照片，其中成形膜层310位于非织物层330的上面。图5还显示了多个有孔凸起316，其具有在相邻的有孔凸起316之间延伸的槽脊区域324。有孔凸起316(图5)和相应的孔326(图3和4)以22目图案排列，并且每个孔326具有六边形(“hex”)形状，如图4的白色虚线所示。
图6是根据本发明的一个实施方案的流体分布材料600的一侧的放大照片，流体分布材料600可以用作图1的流体分布材料140。如所示的，流体分布材料600包含成形膜层610和位于成形膜层610的上面的非织物层630。成形膜层610包含三种不同类型的孔626A、626B、626C，和在孔626A、626B、626C之间延伸的槽脊区域628。如所示的，孔626A、626B、626C以类似于花朵或花卉的图案排列，其中中心的大致圆形的孔626A被四个更小的大致圆形的孔626B和四个椭圆形或卵形的孔626C所包围，每个具有以相对于x-y栅格约45度角延伸的主轴。圆形孔626A、626B在x方向和y方向上可以具有约15个孔/线性英寸的目数(即15目)。非织物层630包含多个连续纤维636，其跨过成形膜层610的槽脊区域628和孔626A、626B、626C延伸。连续纤维636在结合位置640处连接到槽脊区域628。
图7显示了孔626B、626C、槽脊区域628和结合位置640的更近的视图。
图8是图6的流体分布材料600的部分横截面视图的放大照片，其中成形膜层610位于非织物层630的上面。图6还显示了多个有孔凸起616和在相邻的有孔凸起616之间延伸的槽脊区域624。
图9示意性显示了设备900，其可以用于制造本文所述的本发明实施方案的流体分布材料。如所示的，挤出模具902将聚合物熔体帘904挤出到绕着圆筒908旋转的成形结构906上，圆筒908具有借以抽真空的真空狭缝910。聚合物熔体帘904可以包含例如一种或多种聚烯烃材料和表面活性剂，以及一种或多种添加剂例如着色剂。非织物幅材912在层合辊916上从辊914上展开，并且导向熔体帘904，同时熔体帘904在旋转的成形结构906与层合辊916之间的碰撞点918处仍然是熔融的。
非织物幅材912与熔体帘904相邻的纤维在两个层在真空狭缝910上交叉在一起时嵌入熔体帘904的表面，在这里在聚合物幅材(即凝固的熔体帘904)中以与成形结构906提供的大致相同的图案来形成。当聚合物幅材(其凝固来形成例如图2的成形膜层210)有孔时，空气流开始穿过有孔凸起(例如216)，这冷却和凝固了该有孔凸起(例如216)。在非织物的纤维(例如236)嵌入有孔凸起(例如216)之间的槽脊区域(例如228)，由此该非织物在槽脊区域(例如228)结合到成形膜层(例如210)时，通过成形结构906还使聚合物幅材冷却。形成的真空成形层合体920通过剥离辊922牵引离开成形结构906和行进到一个或多个随后的辊924，直到它可以通过卷绕器930卷绕成辊932。另外的辊和/或装置的其他零件可以用于设备900中。
所示的实施方案不打算以任何方式受到限制。例如，在一个实施方案中，设备900还可以包含另外的装置，例如互相啮合的齿轮，如果期望，该齿轮可以用于在纵向或横向上使流体分布材料活化。可以包含在设备900中的其他装置包括但不限于电晕处理设备、打印机、花彩装饰装置、卷轴装置，和另外的可以对真空成形层合体920压印或提供另外的孔的加工装置。
图10-13示意性显示了流体分布材料200如何处理流体侵入1000和将流体侵入1000分布到位于流体分布材料200下面的基材240，其可以是吸收剂芯，如上所述，或者可以是测试过程中所用的吸墨纸，如下所述。虽然如上所述，顶片可以位于流体分布材料200之上，但是为了简单起见，图10-13中没有显示顶片。
如图10所示，流体侵入1000，其示意性表示为多个液滴，引入到流体分布材料200的成形膜层210侧。图11显示了流体吸渗的初始阶段。部分的侵入1000能够进入未阻塞的有孔凸起216并穿过到非织物层230，而其他部分的侵入100被捕集在有孔凸起216之间的槽脊区域224上。当进入有孔凸起216的初始流体排入并沿着非织物层230扩散时，和甚至穿过到下面的基材240时，有孔凸起216之间的流体由于流体的表面张力和成形膜层210的亲水性质而被虹吸到有孔凸起216中，直到流体的全部或基本上全部穿过流体分布材料200的成形膜层210为止，如图12和13所示。虽然令人期望的是非织物层230也是亲水的，但是非织物层230在一些实施方案中可以是疏水的。
实施例
使用上述的设备900生成了一系列的流体分布材料。由美国南卡罗来纳州Simpsonville的Fitesa制造的一种亲水的纺粘非织物物包含多个聚丙烯纤维，并且名义基重是12g/平方米(gsm)，被用作非织物幅材912。将低密度聚乙烯、高密度聚乙烯、二氧化钛和表面活性剂的共混物通过挤出模具902挤出来生成熔体帘904，其在非织物幅材912进料到碰撞点918时流延到不同的成形结构906上来生成具有成形膜层的层合体920，该成形膜层具有有孔凸起和开放区域的不同图案。该成形膜层的基重是约18gsm，从而层合体920的总基重是约30gsm。
开放区域穿过样品的开口的面积与样品的总面积相比的百分比，对于每个样品使用计算机化的视频装置来测量，该装置包括摄影机，使用24×放大倍率的显微镜，和测量对比度的成像软件。一边看着样品的成形膜层侧，一边取样品的放大图像，并且摄影机(其可以经由对比度来从样品的实心部分辨识穿过样品的开口)将数据数字化来计算开放面积百分比。表I汇总了产生的层合(“层合体”)样品，以及测量的各自的开放面积。
表I：流体分布材料(层合体)样品
“层合体”样品 成形膜层有孔凸起图案 开放面积(％)
1 11目六边形 5.4
2 22目六边形 5.5
3 40目六边形 6.3
4 15目花朵形 6.8
图3-5(如上所述)显示了样品2的一部分，和图6-8(如上所述)显示了样品4的一部分。如上面指出的，“目”指的是孔数目/线性英寸，“六边形”指的是孔的形状，和“花朵形”指的是图9所示图案，其具有以花朵或花卉图案排列的不同尺寸和形状的孔。
使用与用于生成样品1-4的成形膜层相同的材料共混物和成形结构来生成仅基重是约18gsm的有孔成形膜，该基重与样品1-4的成形膜层的基重相同。在显微镜下使用24×放大倍率和测量对比度的成像软件来测量每个膜的开放面积(不存在非织物幅材912)。将每个膜样品置于与用于生成样品1-4的层合体相同的纺粘非织物幅材912(即由美国南卡罗来纳州Simpsonville的Fitesa制造的12gsm纺粘聚丙烯非织物幅材)的上面(但是不以任何方式结合)，其中有孔凸起在远离非织物幅材的方向上延伸来形成成形膜和非织物幅材的“堆叠体”。表II汇总了生成的对比堆叠体(“堆叠体”)样品，以及以与层合体样品的开放面积相同的方式测量的各自的开放面积，其中堆叠体的成形膜侧面对摄影机。
表II：对比成形膜/非织物“堆叠体”样品
“堆叠体”样品 成形膜有孔凸起图案 开放面积(％)
5 11目六边形 1.4％
6 22目六边形 2.6％
7 40目六边形 2.4％
8 15目花朵形 2.1％
每个堆叠体样品的开放面积低于具有相同有孔凸起图案的层合体样品的开放面积，这表明层合体样品的非织物层中的纤维可以在有孔凸起的位置处伸展来提供更高的开放面积。不受限于理论(并且再参见图2)，据假定在真空成形层合方法过程中，被吸引穿过非织物层230和成形膜层210的空气会引起位于邻近孔226附近的纤维236分离和在槽脊区域228处以更高的密度聚集，在这里因为成形膜层210中的聚合物在成形结构上冷却而不存在空气流。当成形膜层210中的聚合物凝固时，非织物层230的纤维236在结合位置240处基本上锁定就位，而位于邻近孔226附近的纤维236保持伸展开。
吸渗时间和再润湿测试
测试了全部样品对于用作根据本发明实施方案的流体分布材料的适合性。具体地，对于每个样品，通过奥地利Lenzing Technik GmbH&Co KG的“Lister AC”流体测试装置测定了三个不同测试样本的吸渗时间和再润湿，其是干燥的度量。现在将描述用于测量吸渗时间(“吸渗测试方法”)和再润湿(“再润湿测试方法”)的程序，其分别基于在EDANA测试方法ERT 150.5-02和ERT 151.3-02中概括的原理。将下述的全部测试样本和吸收剂基材、滤纸和吸水纸在23℃±2℃和50％±5％相对湿度调节24小时。
对于吸渗测试方法，将每个测试样本切割成5”×5”(125mm×125mm)的片，并且置于三(3)片4”×4”滤纸(吸墨纸)的堆叠体形式的吸收剂基材上。使测试样本取向为成形膜层面朝上和非织物层与滤纸接触。将具有100mm×100mm基底尺寸和孔且电极延伸到该孔中的500g吸渗板置于测试样本的上面。将5mL流体样品(其模拟尿液，由9.0g/L的分析级氯化钠的去离子水溶液组成，在23±2℃的表面张力是70±2mN/m)从测试样本的表面之上30mm的高度分散到孔中。流体与电极形成闭路，这启动了计时器。当流体完全穿过孔时，电路断开，计时器停止，由此以秒为单位记录了流逝时间或”吸渗时间”。
对于“再润湿测试方法”，在来自于吸渗测试方法的初始侵入之后，将另外的侵入分配到测试样本的中心，其中吸渗板仍然就位。另外的侵入是基于使下面的吸收剂基材完全饱和所需的总侵入(包括来自于吸渗测试方法的初始5mL侵入)，通过将三片滤纸的堆叠体(干燥时)的重量乘以滤纸的负荷因数来计算，并且确定是10mL。移开吸渗板，将具有100mm×100mm基座的4000g再润湿重量置于测试样本上面来使流体彻底扩散到吸收剂基材中。用再润湿重量将两个预称重的5”×5”吸水纸(吸墨纸)靠着测试样本的表面再压2分钟以产生约0.50psi的压力，来模拟坐在尿布上的学步幼儿。称重润湿的吸收纸。将测试样本中的任何残留的湿气转移到吸水纸，并且吸水纸预先测量的干重与吸水纸的湿重之间的差值是“再润湿值”，单位g。下表III列出了每个样品的三个测试样本的平均吸渗时间和再润湿值测试结果。
表III：吸渗时间和再润湿测试结果
样品 说明 吸渗时间(秒) 再润湿值(g)
1 11目六边形层合体 0.97 0.060
2 22目六边形层合体 1.47 0.052
3 40目六边形层合体 2.26 0.074
4 15目花朵形层合体 1.52 0.059
5 11目六边形堆叠体 0.98 0.104
6 22目六边形堆叠体 1.57 0.076
7 40目六边形堆叠体 2.54 0.158
8 15目花朵形堆叠体 1.36 0.107
吸渗时间和再润湿结果还分别在图14和15中做图。如图14所示，具有六边形孔(“hex”)的全部层合体样品的吸渗时间比它们对应的堆叠体样品更快。具有花朵形图案的层合体样品(样品4)的吸渗时间比它对应的堆叠体样品(样品8)稍慢。如图15所示，全部层合体样品(样品1-4)的再润湿值比它们对应的堆叠体样品(样品5-8)低至少30％，并且每个层合体样品(样品1-4)的再润湿值小于0.075，而每个堆叠体样品(样品5-8)的再润湿值大于0.075。
压缩率测试
还测试了全部样品当处于压力下时的厚度，由此可以测定样品的压缩率。使用Testing Machines，Inc.的49-70型机动化的低负荷测微计来测量厚度，该测微计具有直径2英寸的测砧，静重量负荷是298g(0.657磅)，其等价于0.21psi的施加压力，并且停留时间是2至5秒。对于每个样品，在跨过样品的不同位置进行多次测量，将每个样品的测量值取平均来确定每个样品的基线厚度测量值。向测砧增加另外的重量来将施加压力增加到0.31psi，0.40psi，0.50psi和0.60psi。通常将0.50psi看作坐在尿布上的学步幼儿施加的压力。对于每个样品，在跨过样品的不同位置在每个压力进行多次测量，将每个样品在每个压力的测量值取平均。下表IV列出了在不同施加压力下的厚度测试结果。
表IV：在施加压力下厚度测试结果
Figure BDA0002851796160000171
使用在不同压力下的厚度测试结果来计算样品在不同压力下的压缩率，使用在最低压力(即0.21psi)的厚度测量值作为基线。使用下面的等式(1)，对于0.31psi，0.40psi，0.50psi和0.60psi每个施加压力来计算每个样品的压缩率：
压缩率(％)＝(厚度x psi－厚度0.21psi)/厚度0.21psi×100 (1)
其中x是施加压力，厚度x psi是在施加压力时的平均厚度，和厚度0.21psi是在0.21psi施加压力时的平均厚度。结果列于下表V中。
表V：压缩率测试结果
Figure BDA0002851796160000181
压缩率测试结果还显示在图16-19中，其中对于全部样品基线施加压力(即0.21psi)设定为0％。具体地，图16显示了样品1(层合体)和样品5(堆叠体)的结果，它们每个具有成形膜层，带有11目六边形(“hex”)图案的有孔凸起。图17显示了样品2(层合体)和样品6(堆叠体)的结果，它们每个具有成形膜层，带有22目六边形(“hex”)图案的有孔凸起。图18显示了样品3(层合体)和样品7(堆叠体)的结果，它们每个具有成形膜层，带有40目六边形(“hex”)图案的有孔凸起。图19显示了样品4(层合体)和样品8(堆叠体)的结果，其每个具有成形膜层，带有15目花朵形图案的有孔凸起。
生成每组数据的线性趋势线，并且包括在图中。表VI列出了每个样品的相关趋势线的斜率、截距和R2值。
表VI：来自于图16-19的线性趋势线数据的汇总
样品 斜率 截距 R<sup>2</sup>
1 23.27 -4.04 0.96
2 21.81 -3.85 0.96
3 21.53 -4.14 0.90
4 17.42 -3.72 1.00
5 41.16 -8.03 0.99
6 24.02 -5.01 0.98
7 26.45 -5.71 0.99
8 27.19 -4.95 0.98
图16-19和线性趋势线表明，对于每个有孔凸起图案，层合体倾向于具有比堆叠体更平的斜率，这意味着随着施加压力的增加，层合体没有如堆叠体那样大程度的压缩，特别是对于11目六边形和15目花朵形图案而言。不受限于理论，据假定对于层合体，嵌入有孔成形膜的槽脊中的非织物的纤维提供了脚手架结构，这使有孔凸起更好地保持它们的形状，并且没有不具有这种益处的有孔凸起那样大程度的压缩。这种益处可以提供一项特别的优点，使得流体分布材料在使用者穿戴时所经历的施加压力下表现良好。
本发明的实施方案提供了一种流体分布材料，其甚至在吸收剂制品经受压力之后减少了残留湿气。成形膜层(其基重低于已知的仅有膜的采集分布材料)和层合到该成形膜层的非织物层的组合可以提供模量，其足以使流体分布材料转化成期望的吸收剂制品。
本文所述的实施方案代表了许多可能的实施和实施例，并且并非意在必需将本发明限制到任何具体的实施方案。相反，可以对这些实施方案进行不同改变，并且本文所述的不同实施方案的各种组合可以用作本发明的一部分，即使未明确描述，如本领域技术人员将理解的。任何这种改变意在包括在本发明的主旨和范围内，并且受到所附权利要求书保护。
例如，即使测试按照流体分布层取向为使侵入首先接触成形膜层来完成，但是将理解在一些实施方案中，流体分布层可以用于非织物层面对顶片和成形膜层面对吸收剂芯的吸收剂制品中。上面所述和所示的实施方案不意在以任何方式进行限制。

Claims (18)

1.用于吸收剂制品的流体分布材料，该流体分布材料包含：
成形膜层，其具有面朝使用者侧和与该面朝使用者侧相对的面朝服装侧，该成形膜层包含以具有10至40个凸起/线性英寸的图案排列的多个有孔凸起，该凸起每个包含从该面朝使用者侧延伸的连续侧壁，该面朝服装侧具有与该多个有孔凸起对齐的多个孔和位于该孔之间的槽脊区域，该成形膜层的基重是10gsm至25gsm；和
非织物层，其层合到该成形膜层的面朝服装侧，该非织物层包含在该槽脊区域连接到该成形膜层的多个纤维，该非织物层的基重是10gsm至15gsm，
其中该流体分布材料根据再润湿测试方法的再润湿值小于0.075g，和
其中该流体分布材料在0.21psi至0.60psi的压力的压缩率小于10％。
2.根据权利要求1所述的流体分布材料，其中该多个有孔凸起以具有10至25个凸起/英寸的图案排列。
3.根据权利要求1所述的流体分布材料，其中该成形膜层包含表面活性剂。
4.根据权利要求1所述的流体分布材料，其中该非织物层包含纺粘非织物。
5.根据权利要求4所述的流体分布材料，其中该纺粘非织物是亲水的。
6.根据权利要求1所述的流体分布材料，其中该成形膜层包含高密度聚乙烯。
7.用于吸收剂制品的流体管理体系，该流体管理体系包含：
流体分布材料，其包含：
成形膜层，其具有面朝使用者侧和与该面朝使用者侧相对的面朝服装侧，该成形膜层包含以具有10至40个凸起/线性英寸的图案排列的多个有孔凸起，该凸起每个包含从该面朝使用者侧延伸的连续侧壁，该面朝服装侧具有与该多个有孔凸起对齐的多个孔和位于该孔之间的槽脊区域，该成形膜层的基重是10gsm至25gsm，和
非织物层，其层合到该成形膜层的面朝服装侧，该非织物层包含在该槽脊区域连接到该成形膜层的多个纤维，该非织物层的基重是10gsm至15gsm；和
连接到该流体分布材料的顶片，其中该成形膜层的该面朝使用者侧面对该顶片，
其中该流体分布材料根据再润湿测试方法的再润湿值小于0.075g，和
其中该流体分布材料在0.21psi至0.60psi的压力的压缩率小于10％。
8.根据权利要求7所述的流体管理体系，其中该多个有孔凸起以具有10至25个凸起/英寸的图案排列。
9.根据权利要求7所述的流体管理体系，其中该顶片包含有孔成形膜。
10.根据权利要求7所述的流体管理体系，其中该顶片包含非织物幅材。
11.根据权利要求7所述的流体管理体系，其中该顶片包含层合体。
12.根据权利要求7所述的流体管理体系，其中该成形膜层包含高密度聚乙烯。
13.吸收剂制品，其包含：
顶片；
背片；
位于该顶片与该背片之间的吸收剂材料；和
位于该顶片与吸收剂芯之间的流体分布材料，该流体分布材料包含：
成形膜层，其具有面朝使用者侧和与该面朝使用者侧相对的面朝服装侧，该成形膜层包含以具有10至40个凸起/线性英寸的图案排列的多个有孔凸起，该凸起每个包含从该面朝使用者侧延伸并与该顶片接触的连续侧壁，该面朝服装侧具有与该多个有孔凸起对齐的多个孔和位于该孔之间的槽脊区域，该成形膜层的基重是10gsm至25gsm，和
非织物层，其层合到该成形膜层的面朝服装侧，该非织物层包含在该槽脊区域连接到该成形膜层的多个纤维，该非织物层的基重是10gsm至15gsm，
其中该流体分布材料根据再润湿测试方法的再润湿值小于0.075g，和
其中该流体分布材料在0.21psi至0.60psi的压力的压缩率小于10％。
14.根据权利要求13所述的吸收剂制品，其中该顶片包含有孔成形膜。
15.根据权利要求13所述的吸收剂制品，其中该顶片包含非织物幅材。
16.根据权利要求13所述的吸收剂制品，其中该顶片包含层合体。
17.根据权利要求13所述的吸收剂制品，其中该多个有孔凸起以具有10至25个凸起/英寸的图案排列。
18.根据权利要求13所述的吸收剂制品，其中该成形膜层包含高密度聚乙烯。
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JP2021525596A (ja) 2021-09-27
US20190358096A1 (en) 2019-11-28
WO2019226827A1 (en) 2019-11-28
CN112739298A (zh) 2021-04-30
US11160697B2 (en) 2021-11-02
US10500108B1 (en) 2019-12-10
KR20210047825A (ko) 2021-04-30
BR112020024102A2 (pt) 2021-02-17
US10258517B1 (en) 2019-04-16
EP3801423A4 (en) 2022-04-20
US20200113748A1 (en) 2020-04-16

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